Protective packaging assembly

ABSTRACT

A protective packaging assembly and a method of making the same. The packaging assembly is for packaging and protecting one or more articles for shipment. The assembly may include an outer container, an inflatable element, and a framing element. The container defines an interior for holding the article(s), as well as the inflatable element and the framing element. The inflatable element defines a plurality of inflated cells for cushioning and protecting the article or articles against impact and other forces. The framing element has a peripheral shape that corresponds to at least a portion of the interior of the container so that the framing element may be securely held within the interior. The framing element may be operatively connected to the inflatable element to position the inflatable element adjacent to the article in a predetermined manner so that the inflated cells protect the article when the packaging structure is closed.

BACKGROUND OF THE INVENTION

1) Field of the Invention

The present invention relates to protective packaging assemblies, and relates more particularly to packaging assemblies which include inflatable packaging material and a rigid foldable framing element.

2) Description of Related Art

Protective packaging assemblies are often used when an object or article to be packaged requires protection from physical shock or other vibration hazards. For example, when shipping an object that is relatively fragile it is often desirable to package the object inside a box to protect the object from physical impacts that may occur during loading, transit, and unloading. To add additional protection, protective packaging material is often placed within the box. There are numerous types and forms of protective packaging material for this purpose including paper or plastic dunnage and air-cushioning or foam-cushioning structures. In general, the packaging material is intended to control the movement of the object within the box and/or provide a cushioning layer between the object and the box in order to soften or absorb the effects of a physical impact to the box.

In order to be effective the packaging material typically must engage enough of the object to hold it substantially in place and engage the areas of the object likely to bear the physical impact. However, concern about not having enough packaging material, often causes users to compensate by using a great deal more packaging material than necessary. Essentially, this extra packaging material is being wasted and shipped. Alternatively, a user may not use or place enough of the packaging material in the box or, more specifically, position the packaging material in the proper areas to provide for effective protection of the object during transit. Also, in many cases, the packaging material, itself, might move around during transit and, thus, create protection issues.

In light of the foregoing, there remains a need for a packaging assembly that is configured to support, distribute, and place protective packaging material onto and around an object to protect it against impact and other forces.

BRIEF SUMMARY OF THE INVENTION

The present invention may address one or more of the above problems. A protective packaging assembly may have a framing element that is operatively connected to an inflatable element, such as with an adhesive or push-tabs, so that the framing element can position the inflatable element adjacent to the packaged article in a desired manner. As such, the framing element may minimize the amount of protective material required to provide adequate protection and may reduce the protective material that would otherwise be wasted by not providing any protection to the article during shipment. Furthermore, the framing element may help hold the protective material to the article during shipping and, thus, reduces the likelihood of the protective material moving relative to the article during shipment.

Specifically, the packaging assembly may include an outer container, an inflatable element, and a framing element. The outer container defines an interior for holding the article or articles, as well as the inflatable element and the framing element. The inflatable element may define one or more inflated cells for cushioning and protecting the article or articles against impact and other forces. The framing element has an outer peripheral shape that corresponds to at least a portion of the interior of the outer container such that the framing element may be held securely within the interior. The framing element is operatively connected to the inflatable element to position the inflatable element adjacent to the article in a predetermined manner such that the inflated cells may cushion the article.

According to one embodiment, the inflatable element includes at least two layers of a film material. The layers define a plurality of inflated cells. Also, the inflated cells may be interconnected.

One aspect of the invention is the operative connection of the inflatable element to the framing element. For example, a portion of the inflatable element may be adhered to a portion the framing element. Also, one or more foldable tabs may be used to connect the two elements or a portion of the inflatable element may be held and retained by an opening within the framing element.

The present invention also provides a method of constructing the packaging structure for supporting and protecting an article within the outer container. The method may include forming a rigid and foldable framing sheet and operatively connecting a sheet of inflatable material to one side of the framing sheet, and configuring the framing sheet so that the outer peripheral shape of the framing sheet engages the outer container to securely hold the framing sheet within the outer container and an inner cavity region of the framing sheet is at least partially lined with the inflatable element for receiving and cushioning the article.

The step of operatively connecting the sheet of inflatable material to the framing element may include adhering a portion of the inflatable material to the framing element. It may also include inserting at least a portion of the framing element through the sheet of inflatable material.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 is a top view of a framing element according to an embodiment of the present invention;

FIG. 2 is an exploded view of a framing element and an inflatable element according to an embodiment of the present invention;

FIG. 3 is a cross-sectional view taken at line 3-3 of FIG. 2 of a foldable tab of the framing element in a perpendicular position extending through the inflatable element;

FIG. 4 is a perspective view of the packaging structure according to one embodiment of the present invention, wherein two of the side portions of the framing element are in a twice folded position;

FIG. 5 is the packaging structure of FIG. 4, wherein a third side portion is in a twice folded position;

FIG. 6 is the packaging structure of FIG. 5, wherein a fourth side portion is in a twice folded position and an outer extension area of the inflatable element extends across the top of the article;

FIG. 7 is a perspective view of the packaging structure of FIG. 6 being placed within an outer container;

FIG. 8 illustrates three separate inflatable elements according to an embodiment of the present invention; and

FIG. 9 is a partial exploded view of an embodiment of the present invention having two rolled up and separate inflatable elements;

FIG. 10 a is an exploded partial view of a framing element and an inflatable element according to another embodiment of the present invention, wherein the framing element defines an X-shaped opening for engaging the inflatable element; and

FIG. 10 b illustrates a portion of the inflatable element being pushed through the X-shaped opening of FIG. 10 a.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

In general and as shown in the figures, the present invention provides a packaging assembly 10 for packaging and protecting one or more articles 11 for shipment. The assembly may include an outer container 12, an inflatable element 16, and a framing element 26. The outer container 12 defines an interior for holding the article 11, as well as the inflatable element 16 and the framing element 26. The inflatable element 16 defines one or more inflated cells 18 for cushioning at least part of the article 11 from impact or vibration forces. The framing element 26 engages the outer container 12 such that the framing element 26 may be securely held within the interior of the outer container 12. The framing element 26 may also be operatively connected to the inflatable element 16 to position the inflatable element 16 adjacent to the article 11 in a predetermined manner such that the inflated cells 18 cushion the article 11 when the outer container 12 is closed.

More specifically, the outer container 12 may be a shipping box or carton as known in the art. For example and as shown in FIG. 7, the outer container 12 may be a box made from cardboard. Typically, the outer container 12 has an opening and one or more walls. The walls define one or more inner surfaces and an interior for holding one or more articles and the opening provides access to the interior for placing the articles in and out of the container 12. One or more of the walls may have movable edge portions 13 that are configured to close the opening of the container 12 and thus function as a lid or closure for the container 12. In some embodiments, the container may further include a separate lid structure for closing the opening.

As shown best in FIGS. 2 and 3, the inflatable element 16 defines one or more inflated cells 18 for cushioning at least part of the article from impact or other forces. According to one embodiment of the present invention, the inflatable element 16 includes a first sheet of film material and a second sheet of film material. The sheets are joined together defining the plurality of cells 18 between them. The cells 18 may be inflated during the joining of the sheets or afterwards. For example, the inflatable element may be the air cellular material sold under the trade name of Bubble Wrap® by Sealed Air Corporation of Saddle Brook, N.J., wherein the cells are “inflated” by the air trapped within the cells during the manufacturing process of the material. Also, the inflatable element may be what is known in the art as NewAir I.B.™ Barrier Bubble Cushioning, wherein some of the cells are interconnected and inflated after the manufacturing process as described further in U.S. Pat. No. 6,410,119, which is incorporated herein by reference. It should be understood that the extent to which the cells may be inflated or the general volume, size and shape of the cells may vary between the cells. The varying dimensions of the cells allow the inflatable element to accommodate for the varying dimensions of the article and the framing element. The inflatable material may also be material sold under the trade names of AirCap® or Barrier Bubble®, both by Sealed Air Corporation, or other similar materials.

The inflatable element 16 is illustrated as having a generally cross shape with a central area 19 and four outer extension areas 22-25. However, the overall shape of the inflatable element may vary between embodiments.

FIG. 1 illustrates a framing element 26, according to an embodiment of the present invention. The framing element 26 may be formed of any substantially stiff material that is foldable such as paperboard, cardboard, or plastic. For example the framing element 26 may be a corrugated cardboard sheet shaped by a die-cutting process. The framing element 26 may include a central portion 28 and four foldable side portions 30-34. The framing element 26 may also define a series of fold lines 36-43, edge tabs 45, and holes 46 for configuring or folding the framing element 26 such that it forms an outer peripheral shape and an inner cavity region. More specifically, according to the illustrated embodiments, each side portion 30-34 has a first fold line 36-39 that delimits the side portion 30-34 from the central portion 28. Each side portion 30-34 may be foldable along this first fold line such that the side portion is substantially perpendicular to the central portion. Each side portion 30-33 may also include a pair of second fold lines 40-43 extending across the side portions 30-33 and generally parallel to the first fold lines 36-39. Each side portion 30-33 may be foldable again along these second pair of folds lines 40-43 such that the distal edge 48-51 of each side portion extends back toward and proximate to the central portion 28. As one in the art would appreciate, the flange portions 52, 53, 54, 55 extending from some of the side portions 31, 33 along with the edge tabs 45 and holes 46, allow for the side portions 30-33 to be interlocked and supported in a generally perpendicular position to the central portion 28, as seen in FIGS. 4 through 7. The central portion 28 may also include foldable tabs 34, 35.

Although depicted as a generally rectangular shape with four sides, the overall shape and structure of the framing element may vary depending on the intended article for the outer container. More specifically, the inner cavity region may be configured to receive the article, while the outer peripheral shape may be configured to engage the outer container such the framing element may be held securely in place within the interior of the outer container. Therefore the overall shape of the framing element will typically be influenced by the shape of the article and the shape of the outer container.

“Securely held” as used herein generally describes the relationship between the framing element and the outer container. More specifically, the framing element is configured to correspond and engage at least a portion of an inner surface of the outer container such that the framing element is restricted from moving around within the container in at least one direction. One in the art would appreciate that the framing element may be securely held within the container and still be removable from the container or not require the compete closure of the container.

One aspect of the present invention is operatively connecting the framing element and the inflatable element. “Operatively connecting” as used herein generally defines creating one or more interconnections between the two elements or configuring the inflatable element to have a mutual shape with the inner cavity region of the framing element such that at least a portion of the inflatable element may be positioned and held by the framing element. For example, as shown in FIG. 2, a portion of the inflatable element 16 may be attached to the central portion 28 of the framing element 26 by an adhesive 60. Also, FIGS. 2 and 3 illustrate another interconnection between the inflatable element 16 and the framing element 26 by the foldable tabs 34, 35 of the framing element 26. The foldable tabs 34, 35 may be foldable to a generally perpendicular position. The inflatable element 16 may engage these foldable tabs 34, 35 through slits 20, 21 defined in the inflatable element 16. The slits 20, 21 and foldable tabs 34, 35 create another interconnection that operatively connects the inflatable element 16 to the framing element 26.

Yet another example of an interconnection, according to some embodiments of the present invention, is illustrated in FIGS. 10 a and 10 b. FIG. 10 a illustrates an X-shaped opening 40 defined in the central portion 28′ of the framing element 26′. The opening 40 may be configured to receive and retain a portion of the inflatable element 16′ as shown by 41 in FIG. 10 b. Although depicted as an X-shaped opening, any shape or size opening, including cuts formed in the framing elements, may be used that is configured to receive and hold a portion of the inflatable element. Also, although depicted as a two-step process, i.e. providing a framing element with an opening and then pushing the inflatable element through the opening, the process for creating such an interconnection may vary. For example, a punch or similar device may be used to push a portion of the inflatable element through the framing element and, thus, create the opening within the framing element. Pushing a portion of the inflatable element through the framing element is generally referred to herein as a “push-through tab.”

A portion of the inflatable element may be shaped to facilitate one or more interconnections between the framing element and the inflatable element. For example, an edge or other portion of the inflatable element may be T-shaped. The T-shaped edge may be folded and inserted through a cut in the framing element. Once inserted the T-shaped edge is unfolded and the shape of the edge supports a continuing connection between the inflatable element and the framing element.

Furthermore, the inflatable element and the framing element may have interlocking portions. For example, at least a portion of the edges of the inflatable element and the framing element may be dovetailed so as to interlock a portion of the edges together.

FIGS. 2 through 7 illustrate the packaging of an article 11 according to one embodiment of the present invention. FIG. 2 depicts the connecting of the inflatable element 16 to the framing element 26 as described above. A portion of the central area 19 of the inflatable element 16 may be adhered to the central portion 28 of the framing element 26, while the outer extension areas 22-25 may overlie the side portions 30-33 of the framing element 26. FIG. 3 illustrates one of the foldable tabs 34 extending through one of the slits 20 defined in the inflatable element 16.

FIG. 4 illustrates an article 11, such as a laptop computer, placed in a partly formed inner cavity region of the framing element 26 between the two foldable tabs 34, 35. The two side portions 30, 32 extending parallel the edge tabs 34, 35 are in a twice folded position forming generally perpendicular side walls of the inner cavity region. The outer extension areas 22, 24 of the inflatable element 16 corresponding to these side walls 30, 32 are rolled up between the side walls 30, 32 and the foldable tabs 34, 35. These rolled up portions of the inflatable element 16 reinforce the tabs 34, 35 in their generally perpendicular position and thus help prevent the movement of the article 11 in the direction of the foldable tabs 34, 35. The other side portions 31, 33, the ones generally perpendicular to the foldable tabs 34, 35, are in a once folded position with their corresponding outer extensions areas 23, 25 of the inflatable element 16 extending beyond the distal edges 49, 51 of the side portions 31, 33.

FIG. 5 illustrates one of the side portions 33, in the twice folded position, forming a third side wall of the inner cavity region. According to this illustrated embodiment, the corresponding outer extension area 25 of the inflatable element 16 may be contained within the twice folded side portion 33.

FIG. 6 illustrates the last remaining side portion 31 being folded again to form a fourth and last side wall of the inner cavity region and the corresponding outer extension area 23 of the inflatable element 16 extending over the top of the article 11 and being secured to the far side of the article 11 between the third side wall 33 and the article 11.

FIG. 7 illustrates one of the aspects of the present invention. The operatively connected framing element 26 and inflatable element 16 form a packaging structure that may be configured to hold and protect an article 11 as described above. The packaging structure, as shown, fits into the outer container 12. The outer peripheral shape of the framing element 26 may be configured to engage the outer container 12 such that the framing element 26 may be held securely within the outer container 12 and the inflatable element 16, which may be partially positioned by the framing element 26, provides protection to the article 11.

FIGS. 8 and 9 illustrate another embodiment of the present invention. According to this embodiment, the outer extension areas 22, 24 corresponding to the side walls or side portions 30, 32 parallel to the foldable tabs 34, 35 may be separate elements from the first inflatable element 16 that may be operatively connected to the framing element 26. These separate inflatable elements 22, 24 may be rolled and placed between the foldable tabs 34, 35 and side walls 30, 32. Additional separate inflatable elements may be used to provide additional protection. The separate inflatable elements 22, 24 may be made from the same material as the first inflatable element 16 or be of a differing protective cushioning material. Although not illustrated, one in the art would appreciate that any of the additional separate inflatable elements may also be operatively connected to the framing element.

In yet another aspect of the present invention, the inflating of the cells in the inflatable elements may be used to facilitate the configuring or erecting of the framing element into a final shape. For example, the inflation of the cells may facilitate the folding or unfolding of certain areas of the framing element to configure the framing element and its inner cavity region to a shape for receiving the article. Also, as mentioned, the timing of the inflation of these cells may vary. According to one embodiment, one or more of the cells may be inflated after the placing of the article within the inner cavity region. By placing the article in the inner cavity region first, the cells may then be inflated to an optimal level such that the cells substantially occupy any voids between the article and the framing element. Furthermore, the inflation process may be used to facilitate the centering or positioning of the article within the inner cavity region. It should also be noted that the amount of inflation by cell may vary depending on the location of the cells to the article.

According to the illustrated embodiments, the framing element was formed from a process like die-cutting, before the inflatable element was operatively connected thereto. However, in another embodiment, not depicted, the inflatable element and the framing sheet may be adhered together before the die cutting process. For example, a layer of inflatable material may be adhered substantially to a layer of framing material, such as cardboard. Therefore, when the framing element is produced by the die cutting or similar process, the inflatable element substantially lines one side of the framing element. Also, it may not be necessary to inflate every cell of the inflatable element, for example the cells positioned within a side wall as discussed above would not necessarily be inflated. The die-cutting process may be used to deflate or remove inflated cells in order to facilitate the folding of the framing material.

Although the present invention has been described regarding packaging and protecting an article, the invention would equally apply to the packaging of multiple articles. Furthermore, although the inflatable element is illustrated as substantially covering the framing element, the amount of inflatable element connected to the framing element may vary between embodiments. For example, the inflatable element or elements may be placed in a few engagement points between the inner cavity region of the framing element and the article.

The present invention has several features. For example, the framing element may be configured to help support, distribute, and position the inflatable element onto, around, or adjacent to the article to be shipped in order to provide effective protection to the article against shock, vibration, and other forces. Moreover, the framing element may minimize the amount of protective material that is required to provide adequate protection to the article. This, also, may reduce the amount of protective material that would otherwise be wasted by just being along for the ride and not providing any protection to the article during shipment. Furthermore, the framing element may help hold the protective material to the article during shipping and, thus, reduce the likelihood of the protective material moving relative to the article during shipment.

Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

1. A packaging assembly for packaging and protecting an article for shipment, said packaging assembly comprising: an outer container defining an interior for holding the article and having an inner surface; an inflatable element; and a framing element having a peripheral shape corresponding to and engages at least a portion of the inner surface of the outer container such that the framing element is securely held within the outer container, and wherein the inflatable element is operatively connected to the framing element to position the inflatable element adjacent to the article in a predetermined manner so that the inflatable element engages the article to cushion and restrict the movement of the article to the outer container.
 2. The packaging assembly according to claim 1 further comprising an adhesive for operatively connecting the inflatable element to the framing element.
 3. The packaging assembly according to claim 1, wherein the framing element includes at least one foldable tab and the inflatable element defines at least one slit, wherein the tab and slit are engaged to operatively connect the framing element to the inflatable element.
 4. The packaging assembly according to claim 1, wherein the framing element includes an opening configured to receive and retain a portion of the inflatable element so as to operatively connect the inflatable element to the framing element.
 5. The packaging assembly according to claim 1, wherein the framing element is made from corrugated cardboard.
 6. The packaging assembly according to claim 1 further comprising at least two inflatable elements, wherein at least one of the inflatable elements is operatively connected to the framing element.
 7. The packaging assembly according to claim 6, wherein each of the inflatable elements defines at least one inflated cell.
 8. The packaging assembly according to claim 1, wherein the inflatable element includes at least two layers of a film material, the layers defining a plurality of inflated cells between them.
 9. The packaging assembly according to claim 8, wherein at least two of the inflated cells are interconnected.
 10. The packaging assembly according to claim 1 further comprising at least two framing elements, wherein the inflatable element is operatively connected to at least one of the framing elements.
 11. A packaging structure for supporting and protecting an article within an outer container, said packaging structure comprising: an inflatable sheet material for protecting the article, the inflatable sheet material defining a plurality of inflated cells for cushioning at least part of the article from impact forces; a framing element for supporting the article within the outer container, the framing element including an outer peripheral shape configured to engage the outer container such that the framing element is securely held within the outer container, and wherein the inflatable sheet material is operatively connected to the framing element to position at least one of the inflated cells adjacent to the article in a predetermined manner so that the inflated cells cushion the article.
 12. The packaging structure according to claim 11, wherein the framing element includes a first side and a second side and the inflatable sheet material substantially covers the first side and is adhered to at least a portion of the first side.
 13. The packaging structure according to claim 12, wherein at least two of the inflated cells are interconnected.
 14. The packaging structure according to claim 11 further comprising an adhesive for operatively connecting the inflatable sheet material to the framing element.
 15. The packaging structure according to claim 11, wherein the framing element defines at least one foldable tab and the inflatable sheet material defines at least one slit, wherein the tab and slit are engaged to operatively connect the framing element to the inflatable element.
 16. The packaging structure according to claim 11, wherein the framing element includes an opening configured to receive and retain a portion of the inflatable sheet material so as to operatively connect the inflatable sheet material to the framing element.
 17. A method of constructing a packaging structure for supporting and protecting an article within an outer container, said method comprising: forming a rigid and foldable framing element; operatively connecting a sheet of inflatable material to the framing element, the inflatable material defining at least one inflated cell for cushioning at least part of the article from impact forces; and configuring the framing element so that an outer peripheral shape of the framing element engages the outer container to securely hold the framing element within the outer container and the sheet of inflatable material at least partially lines an inner cavity region of the framing element to receive and cushion the article.
 18. The method according to claim 17, wherein the step of operatively connecting the sheet of inflatable material to the framing element includes adhering a portion of the inflatable material to a first side of the framing sheet.
 19. The method according to claim 17, wherein the framing element defines at least one foldable tab and the sheet of inflatable material defines at least one slit, wherein the step of operatively connecting the sheet of inflatable material to the framing element includes inserting at least one foldable tab of the framing element through at least one slit of the sheet of inflatable material.
 20. A method of forming a packaging structure for protecting an article during shipment, the method comprising: attaching an inflatable protective material to a rigid and foldable sheet of material; and folding the sheet of material into a framing element having an outer peripheral shape and an inner cavity region, wherein the inflatable protective material and the inner cavity region is configured to receive the article.
 21. The method according to claim 20, further comprising inflating at least one cell defined by the inflatable protective material so as to provide protection to the article.
 22. The method according to claim 20 further comprising placing the article into the inner cavity region, inflating at least one cell defined by the inflatable protective material so as to provide protection to the article, and placing the framing element, inflatable protective material, and article into an outer container, wherein an outer peripheral shape of the framing element engages the outer container such that the framing element, inflatable protective material, and article are held securely within the container.
 23. The method according to claim to 20, wherein the inflatable protective material and the foldable sheet of material are attached by an adhesive.
 24. The method according to claim 20, wherein the inflatable protective material defines at least one slit and the foldable sheet of material defines at least one foldable tab.
 25. The method according to claim 24, wherein at least one foldable tab of the foldable sheet of material is inserted into at least one slit of the inflatable protective material for attaching the inflatable protective material to the foldable sheet of material. 